CN108202467B - Conveying device and conveying head - Google Patents

Abstract

The present invention relates to a conveying device and a conveying head. The conveying device is provided with a plurality of holding mechanisms and more than 1 pushing mechanism; the holding mechanism includes a holder for holding the molding material and a holder moving mechanism for moving the holder; the pressing mechanism includes a pressing member that is brought into contact with the molding material to press the molding material, and a pressing member moving mechanism that moves the pressing member.

Description

Conveying device and conveying head

Technical Field

The present invention relates to a conveying device and a conveying head, and more particularly to a conveying device and a conveying head used for press molding of a molding material including reinforcing fibers and a thermoplastic resin.

Background

In recent years, fiber-reinforced resin molded articles made of fiber-reinforced resins including reinforcing fibers and thermoplastic resins have been used in a wide range of fields from daily necessities, sports applications to automobiles and aerospace applications because of their various excellent characteristics such as specific strength, specific rigidity, fatigue resistance, and vibration damping properties. Many of them are often formed into a desired product shape by various forming methods and then subjected to a treatment such as a secondary process to obtain a finished product in order to satisfy required characteristics of the product. Therefore, various techniques for molding and processing fiber-reinforced resin molded articles have been vigorously studied and developed.

In addition, conventionally, there has been proposed an apparatus used for press molding using the fiber-reinforced resin as a molding material. Such devices used for pressure molding using a fiber-reinforced resin as a molding material are disclosed in, for example, japanese patent application laid-open nos. 2014-051077 and 2014-168864.

In the above japanese patent application laid-open publication No. 2014-051077, there is disclosed an apparatus for molding a preform by pressing a prepreg (molding material) including reinforcing fibers and a resin with a preform mold. In this apparatus, the prepreg is heated and softened, and then placed in a preform mold that is opened, and the preform is closed and pressure is applied to the mold, thereby forming a preform having a predetermined shape. Then, the preform obtained is placed in a mold for main molding, and is pressed to form a press-molded article.

In the above japanese patent laid-open No. 2014-168864, an apparatus is disclosed: in a state where a base material (molding material) is sandwiched between an upper die and a lower die by pins (upper support pins and lower support pins), the base material is moved to contact the lower die, and after the base material is preliminarily formed into a shape along the uneven shape (curved portion) of the die, the die is closed.

However, in the apparatus disclosed in the above-mentioned Japanese patent application laid-open No. 2014-051077, since the preform is molded by bringing the molding material into contact with the preform mold, the heat of the molding material is taken away by the preform mold, and therefore, the resin flowability of the molding material is lowered, and there is a problem that the pressure formability of the molding material is lowered in the main molding. In japanese patent application laid-open No. 2014-168864, the molding material is supported between the upper mold and the lower mold by being sandwiched by a plurality of pins, but the molding material is also sandwiched by the pins that deform the molding material into a shape along the uneven shape (curved portion) of the mold. If the deformed portion of the molding material is held by the pin from the time point of support, heat of a portion of the molding material corresponding to the deformed portion of the mold, which should most suppress the decrease in resin fluidity, is unnecessarily taken away by the pin, resulting in a problem that the press formability of the molding material is decreased. Further, in the apparatuses disclosed in japanese patent application laid-open nos. 2014-168864 and 2014-168864, in addition to the apparatus for preform shaping and pre-shaping, an apparatus for conveying the shaping material between the upper mold and the lower mold is required, and there is a problem that the structure for conveying the shaping material and preform shaping and pre-shaping becomes complicated.

Disclosure of Invention

The present invention has been made to solve the above-described problems, and 1 object of the present invention is to provide a conveying device and a conveying head capable of conveying and preforming a molding material with a simple configuration and high efficiency while suppressing heat from being taken away from the molding material.

A conveying device according to claim 1 of the present invention is a conveying device that supports a molding material in a molten and softened state including reinforcing fibers and a thermoplastic resin, conveys the molding material between a pair of molds that are opened, and disposes the molding material on one of the pair of molds, the conveying device including a plurality of holding mechanisms and 1 or more pressing mechanisms; the holding mechanism includes a holder for holding the molding material and a holder moving mechanism for moving the holder; the pressing mechanism includes a pressing member that is brought into contact with the molding material to press the molding material, and a pressing member moving mechanism that moves the pressing member. Here, the molten and softened state refers to a state in which the thermoplastic resin in the molding material containing the reinforcing fibers and the thermoplastic resin is heated to a temperature equal to or higher than the melting point of the crystalline thermoplastic resin and the crystalline thermoplastic resin has fluidity, and refers to a state in which the thermoplastic resin in the molding material containing the reinforcing fibers and the thermoplastic resin is heated to a temperature equal to or higher than the glass transition point of the amorphous thermoplastic resin and the amorphous thermoplastic resin is softened and has fluidity, in the case of the amorphous thermoplastic resin. The preforming means that the molding material is formed (deformed) into a predetermined shape so as to follow the die before the press molding by the die.

In the conveying device according to claim 1, as described above, the holding mechanism is provided with a holder that holds the molding material and a holder moving mechanism that moves the holder, and the pressing mechanism is provided with a pusher that presses the molding material in contact therewith and a pusher moving mechanism that moves the pusher. By providing the holding means and the pressing means separately, the pressing tool can be separated from the molding material except during the preforming, and therefore, the pressing tool can be prevented from taking away the hot ribbon of the molding material before the preforming. Therefore, the problem that the heat of the portion of the molding material corresponding to the bent portion of the mold is unnecessarily removed by the pusher and the press formability of the molding material is reduced does not occur.

Further, the molding material is conveyed between the pair of molds opened by the conveying device, and the holding mechanism and the pressing mechanism are provided in the conveying device at the same time, whereby the conveying and preforming of the molding material can be performed efficiently with a simple structure as compared with a case where the conveying mechanism, the holding mechanism, and the pressing mechanism are provided in different devices.

As described above, the conveying device can efficiently convey and preform the molding material with a simple structure while suppressing a decrease in resin fluidity in a portion of the molding material corresponding to the deformed portion of the mold. As a result, the moldability of press molding can be improved, and a highly accurate press molded body (a press molded body with good appearance) can be manufactured.

Further, since the conveying device can directly press the molding material by the pressing mechanism in a state of supporting the molding material, the preforming can be performed without the molding material contacting the mold. As a result, since the press molding can be performed immediately after the preformed molding material is placed in the die, the moldability of the press molding can be improved, and as a result, a highly accurate press-molded article (a press-molded article with good appearance) can be manufactured.

The conveying device according to claim 1 preferably further comprises a control device for controlling the conveying operation and the arranging operation of the molding material; the control device is configured to control the holding mechanism to hold each part of the molding material by the plurality of holders in a state where the pusher is not in contact with the molding material, and to convey the molding material between the pair of dies while supporting the molding material; starting preforming by controlling the holding mechanism and the pressing mechanism before the molding material comes into contact with one of the molds, the preforming pressing the molding material held by the plurality of holders by a pressing tool and deforming the molding material into a predetermined shape so as to follow the one of the molds; the holding mechanism is controlled to release the holding of the molding material after the preforming by the holder, and the molding material is arranged on one of the pair of dies. With this configuration, the timing of the various operations is controlled by the control device, and the molding material is supported by the plurality of holders while the pressing tool and the molding material are not in contact with each other before being conveyed between the pair of dies, so that the pressing tool can be prevented from removing heat from the molding material during conveyance.

In the transport apparatus according to claim 1, it is preferable that the transport apparatus further includes a transport apparatus main body and a transport head attached to the transport apparatus main body, and the transport head includes a plurality of holding mechanisms and 1 or more pushing mechanisms. With this configuration, since the holding mechanism and the pressing mechanism are provided on the transfer head, the holding mechanism and the pressing mechanism can be smoothly interlocked with each other, and the operation time required for molding 1 press-molded body can be shortened. This can suppress unnecessary heat dissipation of the molding material, and thus can suppress a decrease in the temperature of the molding material. As a result, a press-formed body having good appearance (a high-precision press-formed body) can be manufactured.

In this case, it is preferable that the transport head includes a head main body having a mesh-like skeleton structure to which a plurality of holding mechanisms and 1 or more pushing mechanisms are attached. With this configuration, the head main body can be made lightweight, and therefore, when the head main body is operated, the load acting on the conveying device main body can be reduced. Therefore, the conveying operation speed of the head main body (conveying head) can be made higher, and therefore, the operation time required for molding 1 press-molded body can be shortened. This suppresses unnecessary heat dissipation from the molding material, and thus can suppress a decrease in the temperature of the molding material. As a result, a press-formed body with better appearance (a press-formed body with higher accuracy) can be manufactured.

In the above-described aspect in which the transport head includes the head main body, the head main body preferably includes a mounting portion that is provided in the vicinity of an edge portion of the head main body having the mesh-like skeleton structure and that is mounted to the transport apparatus main body. With this configuration, since the mounting portion is provided near the edge portion of the head main body, only the head main body can enter between the dies (the upper die and the lower die), and the conveyor main body cannot enter between the dies (the upper die and the lower die), the distance of opening the dies (the distance between the upper die and the lower die) can be minimized. Therefore, the time required for the mold opening operation can be shortened, and therefore, the operation time required for molding 1 press-molded body can be shortened. This suppresses unnecessary heat dissipation from the molding material, and thus can suppress a decrease in the temperature of the molding material. As a result, a press-formed body with better appearance (a press-formed body with higher accuracy) can be manufactured.

In the above-described aspect in which the head main body includes the mounting portion, it is preferable that the conveying device main body or the mounting portion has a joint portion; the head main body is attached to the transport apparatus main body via a joint portion. With this configuration, the head main body is attached to the transport apparatus main body via the joint portion, and therefore the head main body can be moved flexibly and widely with respect to the transport apparatus main body. This allows the preformed molding material to be smoothly disposed in one of the pair of dies.

In the aspect further including the above-described conveying device main body and the conveying head, it is preferable that the holder moving mechanism includes a holder rotation restricting mechanism that restricts rotation of the holder about a moving direction of the holder by the holder moving mechanism and maintains an orientation of the holder in a predetermined direction; the pusher moving mechanism includes a pusher rotation restricting mechanism that restricts the rotation of the pusher in the moving direction of the pusher by the pusher moving mechanism and maintains the orientation of the pusher in a predetermined direction. With this configuration, the holder rotation restricting mechanism and the pusher rotation restricting mechanism can maintain the respective orientations of the holder and the pusher, thereby suppressing positional deviation of the holder and the pusher with respect to the molding material.

In the above-described aspect further including the transport apparatus main body and the transport head, it is preferable that the number of the holding mechanisms provided in the transport head is larger than the number of the pushing mechanisms provided in the transport head. With this configuration, the molding material can be stably held by the holding mechanisms larger in number than the pressing mechanisms.

In the above-described aspect further including the transport apparatus main body and the transport head, the transport apparatus main body is preferably an articulated robot. With this configuration, the molding material can be appropriately conveyed through various conveyance paths corresponding to the press-molded bodies of various shapes.

In the transport device according to claim 1, it is preferable that the holder moving mechanism and the pusher moving mechanism each have an air cylinder. With this configuration, the retainer and the pusher can be linearly reciprocated by a simple structure including an air cylinder. Further, since the weight of the transport head can be reduced by using the air pressure cylinder, the load acting on the transport apparatus main body can be reduced when the head main body is operated. As a result, the conveyance operation speed of the head main body (conveyance head) can be made higher.

In the transport device according to claim 1 above, it is preferable that the holding mechanism includes a sliding mechanism that slides the holder in a direction intersecting a moving direction of the holder by the holder moving mechanism. With this configuration, the distance between the retainer and the pusher can be adjusted by sliding the retainer by the slide mechanism, and therefore, the molding material can be prevented from being excessively stretched and excessively thinned during preforming. As a result, a press-formed body with higher accuracy can be manufactured.

In this case, it is preferable that the sliding mechanism has an empty pneumatic cylinder. With such a configuration, the retainer can be linearly reciprocated in a direction intersecting the moving direction of the retainer by the retainer moving mechanism with a simple configuration including an air cylinder. Further, since the weight of the transport head can be reduced by using the air pressure cylinder, the load acting on the transport apparatus main body when the head main body is operated can be reduced. As a result, the transport operation speed of the head main body (transport head) can be made higher.

In the aspect in which the holding mechanism includes a slide mechanism, it is preferable that the plurality of holding mechanisms include: a1 st holding mechanism having a1 st holder and a1 st sliding mechanism for sliding the 1 st holder in a1 st direction; a2 nd holding mechanism having a2 nd holder and a2 nd sliding mechanism for sliding the 2 nd holder in a2 nd direction orthogonal to the 1 st direction in a plan view; and a 3 rd holding mechanism having a 3 rd holder and a 3 rd sliding mechanism for sliding the 3 rd holder in a 3 rd direction different from the 1 st direction and the 2 nd direction in a plan view. With this configuration, the molding material can be slid in 2 directions orthogonal to each other and in a direction different from the 2 directions orthogonal to each other in a plan view, and therefore the molding material can be preformed into a complicated shape such as a shape having overlapping portions.

In the transport apparatus according to claim 1, the pusher is preferably formed in a spherical shape, a conical shape, a pyramidal shape, a rod shape, or a plate shape. With this configuration, the preform can be performed even for a molding material having a more complicated shape by the pressing tools having various shapes.

In the conveying device according to claim 1 above, it is preferable that the retainer includes 1 or more retaining needles that retain the molding material by being pierced into the molding material. With this configuration, the molding material can be held with a smaller contact area (contact area between the holder and the molding material) than when the molding material is held with the flat surface in contact with the flat surface, and therefore, heat of the molding material can be more effectively prevented from being carried away by the holder. As a result, even in the case of a press-molded article having a complicated shape, heat transfer from the molding material can be suppressed, and a press-molded article having a good appearance (a highly accurate press-molded article) can be produced.

In this case, it is preferable that the holder includes a plurality of holding needles; the plurality of holding needles are arranged symmetrically with respect to a center line of the holder, the center line extending in a moving direction of the holder by the holder moving mechanism. With this configuration, since the force can be uniformly applied to the molding material when the molding material is held by the holder, it is possible to suppress positional deviation of the molding material and extension of the molding material due to the positional deviation.

In the transport device according to claim 1, the holding needle is preferably formed in an arc shape and is configured to be rotatable in the arc shape. With this configuration, the holding pin is rotated and inserted into the molding material, so that the holding pin is less likely to be pulled out from the molding material, and the molding material can be held more reliably.

According to the invention of claim 2 of the present application, the transfer head supports a molten and softened molding material containing reinforcing fibers and a thermoplastic resin, and includes a plurality of holding mechanisms and 1 or more pressing mechanisms; the holding mechanism includes a holder for holding the molding material and a holder moving mechanism for moving the holder; the pressing mechanism includes a pressing member that is brought into contact with the molding material to press the molding material, and a pressing member moving mechanism that moves the pressing member.

In the transport head according to claim 2, as described above, the holding mechanism is provided with a holder for holding the molding material and a holder moving mechanism for moving the holder, and the pressing mechanism is provided with a pusher for pressing the molding material in contact therewith and a pusher moving mechanism for moving the pusher. By providing the holding mechanism and the pressing mechanism separately, the pressing tool can be separated from the molding material other than at the time of preforming, and therefore, the pressing tool can be prevented from removing heat from the molding material before preforming. Therefore, the problem that the heat of the portion of the molding material corresponding to the bent portion of the mold is unnecessarily removed by the pusher and the press formability of the molding material is reduced does not occur.

Further, the molding material is conveyed between the pair of molds opened by the conveying head, and the holding mechanism and the pressing mechanism are provided at the same time in the conveying head, whereby the conveying and preforming of the molding material can be performed efficiently with a simple structure, as compared with a case where the structure for conveying, the holding mechanism, and the pressing mechanism are provided in different apparatuses.

As described above, the transfer head can efficiently transfer and preform a molding material with a simple structure while suppressing a decrease in resin flowability in a portion of the molding material corresponding to a deformed portion of a mold. As a result, the moldability of press molding can be improved, and a highly accurate press molded body (a press molded body with good appearance) can be manufactured.

Further, since the transfer head can be directly pressed by the pressing mechanism in a state of supporting the molding material, the preforming can be performed without the molding material contacting the mold. As a result, since the press molding can be performed immediately after the preformed molding material is placed in the die, the moldability of the press molding can be improved, and as a result, a highly accurate press-molded article (a press-molded article with good appearance) can be manufactured.

Drawings

Fig. 1 is a schematic diagram showing an overall configuration of a conveyance system including a conveyance device according to an embodiment.

Fig. 2 is a perspective view illustrating a lower mold according to an embodiment.

Fig. 3 is a perspective view showing a conveyance device before sliding according to an embodiment.

Fig. 4 is a plan view showing a conveying device before sliding according to an embodiment.

Fig. 5 is a plan view showing a conveying apparatus after sliding according to an embodiment.

Fig. 6 is a perspective view showing a holding mechanism of a transport apparatus according to an embodiment.

Fig. 7 is a perspective view for explaining the movement of the holding mechanism of the transport apparatus according to an embodiment.

Fig. 8 is a perspective view showing a pressing mechanism of a transport device according to an embodiment.

Fig. 9 is a perspective view showing a molded material after preforming by the conveying device according to an embodiment.

Fig. 10 is a schematic view showing a transport apparatus according to a1 st modification of an embodiment.

Fig. 11 is a schematic diagram showing a pressing mechanism according to a2 nd modification of an embodiment.

Fig. 12 is a schematic view showing a holding needle of a holder according to modification 3 of an embodiment.

Fig. 13 is a schematic view showing a pusher according to a 4 th modification of an embodiment.

Fig. 14 is a schematic view showing a holding pin of the holder according to the 5 th modification of the embodiment.

Detailed Description

Hereinafter, embodiments embodying the present invention will be described with reference to the drawings.

First, a conveying apparatus 100a according to an embodiment will be described with reference to fig. 1 to 9. The transport apparatus 100a is a component of the pressure system 100.

(construction of pressure System)

The press system 100 shown in fig. 1 is used to form a press-formed body M1 of a complicated shape from a forming material M containing reinforcing fibers and a thermoplastic resin. Specifically, the pressure system 100 is used for manufacturing structural parts of automobiles and the like. With this press system 100, a large amount of press-formed bodies M1 can be formed at low cost.

The press system 100 includes a conveying device 100a and a press device 100b to which a pair of dies K (an upper die K1 and a lower die K2) can be attached. Further, the pressure system 100 may include a heating device 101 disposed upstream of the conveying device 100 a. The molding by the press system 100 mainly includes 3 steps of a conveying step, a preforming step, and a press molding step (main molding step). The conveying step and the preforming step are performed by the conveying apparatus 100 a. The press forming process is performed by the press apparatus 100 b. The heating step of heating the molding material M to a molten and softened state before the conveying step is performed by the heating device 101.

Specifically, the press system 100 is configured to convey the molding material M heated by the heating device 101 (heating step) to a molten and softened state to the press device 100b (between the upper mold K1 and the lower mold K2) by the conveying device 100a (conveying step). The pressure system 100 is configured to perform preforming (preforming step) on the conveyed molding material M (or the molding material M during conveyance) by the conveyance device 100 a. Further, the press system 100 is configured to press-mold (mold clamping) the preformed molding material M by the press device 100b (press molding step) to mold the press-molded body M1.

The molten and softened state is a state in which the molding material M is molten and softened and has fluidity. More specifically, when the thermoplastic resin in the molding material M containing the reinforcing fibers and the thermoplastic resin is a crystalline thermoplastic resin, the thermoplastic resin is heated to a temperature equal to or higher than the melting point of the crystalline thermoplastic resin and the crystalline thermoplastic resin has fluidity, and when the thermoplastic resin in the molding material M containing the reinforcing fibers and the thermoplastic resin is a non-crystalline thermoplastic resin, the thermoplastic resin is heated to a temperature equal to or higher than the glass transition point of the non-crystalline thermoplastic resin and the non-crystalline thermoplastic resin is softened and has fluidity.

The preforming means forming before press forming, that is, forming (deforming) the spread flat sheet-like molding material M in a molten and softened state before forming into a predetermined shape along the die K before press forming by the die K. When the molding material M in a molten and softened state is not preformed but is press-molded by being placed in the mold K as it is, the flowability of the molding material M cannot follow the shape change of the molding material M by the mold K, and there is a case where a defect such as a thin portion or a wrinkle locally occurs in the press-molded product M1 obtained by the press molding. In order to prevent such a problem, preforming is performed in which the molding material M is deformed in advance in accordance with the shape and contour of the mold K before press molding.

(Metal mold)

As shown in fig. 2, the lower die K2 has, for example, 3-direction surfaces K21 to K23 intersecting each other. Further, the molding material M is set on the lower die K2 by the conveyor 100a so as to be in contact with the 3-direction surfaces K21 to K23. In fig. 2, the preformed molding material M is indicated by a two-dot chain line. By the preforming, the molding material M is deformed from a flat shape (sheet shape) to a three-dimensional shape along the surfaces K21 to K23. The curved portion (bent portion) of the three-dimensional molding material M after the preforming is formed by pressing the proximal portion with the later-described pressing tools 61a to 61c at the time of preforming. Further, a pipe (not shown) using pressurized water as a heat medium is provided in the mold K for temperature adjustment. The temperature of the mold K is adjusted to, for example, 150 degrees via a pipe.

(Molding Material)

A molding material M used for molding the press-molded body M1 in the press system 100 shown in fig. 1 will be described.

As described above, the molding material M contains reinforcing fibers and a thermoplastic resin. In short, the molding material M is a material in which the reinforcing fibers and the thermoplastic resin are integrated. Specifically, the molding material M is a material obtained by integrating a reinforcing fiber mat as a reinforcing fiber with a thermoplastic resin to form a sheet, or a material obtained by dispersing discontinuous fibers as a reinforcing fiber in a thermoplastic resin to form a sheet. In the present embodiment, the thickness of the molding material M including the reinforcing fibers is about 1 to 5 mm.

The reinforcing fiber is a fiber added to the thermoplastic resin for the purpose of, for example, improving the strength of the molding material M. That is, the reinforcing fibers are reinforcing fibers for reinforcing the molding material M. The reinforcing fibers are appropriately selected depending on the use of the press-formed body M1, and the material is not particularly limited. As the reinforcing fiber in the present embodiment, any of inorganic fibers and organic fibers can be used. Examples of the inorganic fibers include carbon fibers, glass fibers, tungsten carbide fibers, ceramic fibers, alumina fibers, boron fibers, natural fibers, mineral fibers, and metal fibers. Examples of the organic fiber include fibers made of resin materials such as polypropylene-based, polyamide, and polyolefin.

When discontinuous carbon fibers (carbon fibers) are used as the reinforcing fibers, the weight-average fiber length is preferably selected to be in the range of 2mm to 500 mm. More preferably, it is selected so as to fall within the range of 5mm to 100 mm. More preferably, it is selected so as to fall within the range of 10mm to 30 mm. The weight-average fiber length is a value obtained by Σ (L1 × W)/Σ W, where L1 is the fiber length, W is the weight, and L2 (= Σ L1) is the total length of N fibers.

The thermoplastic resin is appropriately selected depending on the use of the press-molded article M1, and the material is not particularly limited. Examples of the thermoplastic resin include polyolefin resins such as polyethylene resins and polypropylene resins, polystyrene resins, polyamide resins, polyester resins, polycarbonate resins, and acrylic resins.

(heating device)

The heating apparatus 101 shown in fig. 1 heats the molding material M to a molten and softened state. The heating device 101 includes a heating device main body 101a, a conveyor 101b, and a plurality of heaters 101 c.

The heating device main body 101a is provided with a passage 101d that penetrates the heating device main body 101a, and a conveyor 101b is inserted into the passage 101 d. The plurality of heaters 101c are disposed along the conveyor 101b on the inner surface of the heating device main body portion 101a constituting the passage 101 d. A tray T on which the spread molding material M before the heat treatment is placed on one end (entrance portion) of the conveyor 101 b. The molding material M is heated by the plurality of heaters 101c while moving from one end (inlet portion) to the other end (outlet portion) by the conveyor 101b, and is in a molten and softened state. The molding material M heated by the heating device 101 has a sheet shape (flat shape).

The conveyor 101b includes a movement restricting portion 101e fixedly provided at the other end portion (outlet portion). The movement restricting section 101e is configured to stop the molding material M at a predetermined position by abutting on the molding material M (tray T) moved by the conveyor 101b to restrict the movement of the molding material M. The predetermined position at which the molding material M is stopped by the movement restricting portion 101e is a position at which the molding material M is held by the conveying device 100a (holders 50a to 50g described later). In short, the movement restricting portion 101e is configured to position the molding material M with respect to the conveying device 100 a.

(pressure device)

The press apparatus 100b shown in fig. 1 is configured to be able to mount a pair of dies K (an upper die K1 and a lower die K2). The press apparatus 100b includes an upper plate 102a that vertically moves to fix the upper mold K1, and a lower plate 102b that fixes the lower mold K2. That is, the press apparatus 100b is a so-called vertical mold press (vertical mold press) that moves the mold K (upper mold K1) in the vertical direction. The upper die K1 has a convex shape, and the lower die K2 has a concave shape corresponding to the upper die K1. The press apparatus 100b is configured to perform preforming by the conveyor 100a, and to press-mold the molding material M placed on the lower die K2 by the conveyor 100a, thereby molding the press-molded body M1.

(conveying device)

The transport apparatus 100a shown in fig. 1 includes an articulated robot 1 and a transport head 2 attached to the articulated robot 1. The articulated robot 1 is provided with a control device 3 for controlling the articulated robot 1 and the transfer head 2. The articulated robot 1 is an example of the "conveyor main body" in the claims.

The articulated robot 1 is a device for moving the transfer head 2. More specifically, the articulated robot 1 is a device for moving the transfer head 2 to a position (holding position) between a position (holding position) at which the transfer head 2 can hold the molding material M heated by the heating device 101 and a mold K for press molding the molding material M. The base of the articulated robot 1 is fixedly disposed on the ground.

As shown in fig. 3, the articulated robot 1 includes an arm portion 10. The arm portion 10 includes a plurality of rod-shaped link members 10a and an intermediate joint portion 10b connecting the link members 10 a. The arm portion 10 has a distal end joint portion 10c (may include a robot hand) at a distal end thereof, which is connected to a later-described mounting portion 40 of the transport head 2 (head main body 4). The distal end joint portion 10c mounts the transport head 2 to the articulated robot 1 such that the transport head 2 can freely rotate in either the vertical direction or the horizontal direction. The distal end joint portion 10c is an example of the "joint portion" in the claims.

The transport head 2 includes a head main body 4, a plurality of holding mechanisms 5 (5 a, 5b, 5c, 5d, 5e, 5f, 5 g), and a plurality of pressing mechanisms 6 (6 a, 6b, 6 c). The holding mechanism 5 and the pressing mechanism 6 are attached to the head main body 4.

(head body)

The head main body 4 has a rectangular outer shape as shown in fig. 3. The head main body 4 has a mesh-like (lattice-like) skeleton structure. Specifically, the head main body 4 is formed in a mesh shape (lattice shape) in which a cross-shaped beam member is arranged orthogonally inside a rectangular frame and the inner region 4 of the rectangular frame is equally divided. With this mesh-like skeleton structure, the weight of the transport head 2 held by the articulated robot 1 is reduced.

In addition, the direction in which one side of the rectangular frame extends is defined as the a direction, and the direction in which the other side that intersects the side that extends in the a direction extends is defined as the B direction. In the drawings, a direction substantially perpendicular to the a direction and the B direction is referred to as a C direction (substantially vertical direction). Further, when the molding material M is conveyed, the head main body 4 is moved in a posture in which the a direction and the B direction are substantially along the horizontal direction and the C direction is substantially along the vertical direction. The direction a is an example of the "direction 1" in the claims. The B direction is an example of the "2 nd direction" in the claims.

The head body 4 is provided with an attachment portion 40 to be attached to the articulated robot 1. The head main body 4 is attached to the articulated robot 1 via the distal end joint portion 10c of the articulated robot 1. The attachment portion 40 is provided in the vicinity of the edge portion of the head main body 4 having a mesh-like skeleton structure. Specifically, the mounting portion 40 is provided adjacent to an edge portion (rectangular frame) of the head main body 4 having the skeleton structure.

(holding mechanism)

As shown in fig. 3 to 6, each of the plurality of holding mechanisms 5 (5 a, 5b, 5C, 5d, 5e, 5f, 5 g) includes a holder 50 (50 a, 50b, 50C, 50d, 50e, 50f, 50 g) and a holder moving mechanism 51 (51 a, 51b, 51C, 51d, 51e, 51f, 51 g) for moving the holder 50 in the C direction. The retainers 50a and 50b are an example of the "retainer 1" in the claims. The retainers 50c and 50d are an example of the "retainer 2" in the claims. The retainer 50g is an example of the "retainer 3" in the claims.

As shown in fig. 6, the holder moving mechanism 51 (51 a, 51b, 51c, 51d, 51e, 51f, 51 g) includes an air cylinder 511.

The air cylinder 511 includes a cylinder tube 511a and a piston rod 511c, and the piston rod 511c extends from a piston (not shown) that reciprocates inside the cylinder tube 511a by supply and discharge of compressed air, protrudes from a base 511b of the cylinder tube 511a, and reciprocates in synchronization with the piston.

The retainer 50 is attached to a distal end portion (an end portion on the opposite side of the piston, an end portion on the C2 direction side) of the piston rod 511C.

The holder moving mechanism 51 further includes a cylinder base 512 to which a base portion 511b of the cylinder tube 511a is attached. The cylinder block 512 has through holes 512a on both sides thereof in the same direction as the direction of reciprocation of the piston rod 511c, with the mounting position of the cylinder tube 511a as the center. That is, 1 through hole 512a is provided on each side of the mounting position of the cylinder tube 511 a.

Further, the holder moving mechanism 51 further includes a guide rod 513. The guide rod 513 is inserted into 1 of the 2 through holes 512a of the cylinder block 512. The guide rod 513 is an example of the "holder rotation restricting mechanism" in the claims.

The guide rod 513 has a stopper 513a at one end (an end on the side of the cylinder 511a, an end on the C1 direction), and the stopper 513a has a shape larger than the cross section of the through hole 512 a. Further, a retainer 50 (a retainer main body 501 described later) is attached to the other end (end in the C2 direction) of the guide rod 513.

The cylinder block 512 is disposed in a plane in which the head main body 4 extends. The air cylinder 511 is configured to be able to move the holder 50 in the C direction. That is, the forming member M can be linearly reciprocated in the C direction.

The stopper 513a is a member that defines a stroke (movement amount) when compressed air is supplied to the air cylinder 511 and the piston rod 511c protrudes from the cylinder 511 a. Further, the stopper 513a is a member that defines the amount of movement of the reciprocal movement of the holder 50. When the piston rod 511C protrudes and the retainer 50 moves, the guide rod 513 having one end attached to the retainer 50 is also guided by the retainer 50 and protrudes from the cylinder block 512, but the retainer 50 stops after the stopper 513a abuts on the cylinder block 512 in the C2 direction (after the state shown in fig. 7 is changed to the state shown in fig. 6).

The guide rod 513 is configured to guide the holder 50 so as not to be inclined with respect to the reciprocating direction of the holder 50 (the direction in which the piston rod 511C protrudes, the C direction).

Further, the guide lever 513 has a function of rotation prevention such that the holder 50 does not rotate about the reciprocating direction of the holder 50 (the direction in which the piston rod 511C protrudes, the C direction). For example, if the piston rod 511c rotates about its center axis (in the direction of R1), the holder 50 attached to the distal end portion of the piston rod 511c also rotates, and the orientation of the holder 50 changes. The guide lever 513 is configured to restrict the rotation and maintain the orientation of the holder 50 in a predetermined direction (the direction in which the holder 50 is moved in the C direction by the holder moving mechanism 51).

The number of holding mechanisms 5a to 5g provided on the transport head 2 (total 7) is larger than the number of pressing mechanisms 6a to 6c provided on the transport head 2 (total 3) described later.

As shown in fig. 6, the holding mechanisms 5a to 5g each include a guide rod 513. In fig. 3 to 5, the guide bar 513 is not shown for convenience.

The holding mechanisms 5a to 5e are configured to grasp and hold the edge portion of the sheet-like molding material M before preforming. The holding mechanisms 5a to 5e are arranged so as to be substantially evenly distributed on the edge portion of the molding material M. The holding mechanisms 5f and 5g are configured to grasp and hold the vicinity of the center of the molding material M. The molding material M has a slightly smaller outer shape than the head main body 4 in a plan view (as viewed from the C direction). Further, the corners of the molding material M on the a1 direction side and the B2 direction side are cut off. Further, the molding material M is held on the C2 direction side of the head main body 4.

The holding mechanisms 5a and 5B are disposed in the region in the a1 direction and the B1 direction among the 4 inner regions of the head main body 4. The holding mechanisms 5c and 5d are arranged in the region in the a2 direction and the B2 direction among the 4 inner regions of the head main body 4. The holding mechanisms 5e and 5f are arranged in the region in the a2 direction and the B1 direction among the 4 inner regions of the head main body 4. The holding mechanism 5g is disposed in a region in the a1 direction and the B2 direction among the 4 inner regions of the head main body 4.

The holding mechanisms 5a and 5b hold a part of the molding material M that is in contact with the surface K22 (see fig. 2) of the lower mold K2 by the preforming. The holding mechanisms 5c and 5d hold a part of the molding material M that is in contact with the surface K23 (see fig. 2) of the lower mold K2 by the preforming. The holding mechanisms 5e, 5f, and 5g hold a part of the molding material M that is in contact with the surface K21 (see fig. 2) of the lower mold K2 by the preforming.

Each of the retainers 50a to 50g includes a retainer main body 501, a plurality of (4 in total) retaining needles (barbed needles) 502 rotatably attached to the retainer main body 501, and a retaining needle driving mechanism (not shown) disposed in the retainer main body 501.

As shown in fig. 6, each holding needle 502 is configured to engage with the molding material M by being inserted into the molding material M. Further, the holding pin 502 is formed in an elongated conical shape (a shape in which the tip of the circular cross section is tapered). The holding pin 502 is formed in an 1/4 arc shape (arc shape of pi/2), and is configured to be rotatable in the E direction in the arc shape by the holding pin driving mechanism. The holding needle driving mechanism is constituted by an air cylinder (not shown) or the like.

The two holding pins 502 are 1 group, and the 1-group holding pins 502 are arranged on the same straight line and are configured to be pierced by moving (rotating) in directions away from each other on the same straight line. Thus, the holding pins 502 are configured to hold the molding material M while suppressing the occurrence of wrinkles in the molding material M. Further, the 1 group of holding needles 502 of the holding mechanisms 5a to 5d, 5g are arranged along the direction in which the edge portion of the molding material M extends.

The plurality of retainer pins 502 provided in 1 retainer 50 (50 a to 50 g) are arranged symmetrically with respect to the center line of the retainers 50 (50 a to 50 g) extending in the moving direction (C direction) of the retainers 50 (50 a to 50 g) by the retainer moving mechanisms 51 (51 a to 51 g). In short, the plurality of retainer pins 502 are mounted in a well-balanced manner with respect to the retainer body 501.

The thickness of the retaining pin 502 is preferably 2 times or less the thickness of the molding material M. This is because, if the thickness of the retaining needle 502 is larger than 2 times the thickness of the molding material M, it is difficult to insert the retaining needle 502 into the molding material M and stably lift (hold) the molding material M.

As an example, the retaining pin 502 is formed from a spring steel material (SUP 10). In addition, the holding pin 502 is manufactured by dividing a round wire rod having a wire diameter of 2mm (thickness) and a diameter of 40mm into 4 parts, and then grinding one end of the wire rod into a needle shape, for example. The holding needle 502 is preferably an arc-shaped needle having a thickness of the molding material M of +5mm or more and an approximate radius of curvature 40 times or less the thickness of the molding material M. More preferably, the needle is formed into an arc shape having a thickness of the molding material M of +8mm or more and an approximate radius of curvature of 20 times or less of the thickness of the molding material M. More preferably, the needle is formed into an arc shape having a thickness of the molding material M of +10mm or more and an approximate radius of curvature of 15 times or less of the thickness of the molding material M.

The holding pin 502 is preferably surface-treated at least at a part of the tip side in order to prevent a part (molten thermoplastic resin) of the molding material M from adhering when the holding of the molding material M is released. Examples of the surface treatment include various release agents, coating agents, and coatings made of fluorine resins such as Polytetrafluoroethylene (PTFE). By such surface treatment, the durability and the peeling effect of the retaining pin 502 are improved.

(sliding mechanism)

Among the plurality of holding mechanisms 5 (5 a, 5B, 5c, 5d, 5e, 5f, 5 g), as shown in fig. 4 and 5, the holding mechanisms 5a, 5B, 5c, 5d, 5g include a slide mechanism 52 (52 a, 52B, 52c, 52d, 52 g) that moves (slides) the respective holders 50a, 50B, 50c, 50d, 50g along the surface (the surface extending in the a direction and the B direction) of the head main body 4.

The slide mechanism 52 includes an air cylinder 521. Since the slide mechanisms 52a to 52d, and 52g have the same configuration, the slide mechanism 52a shown in fig. 4 will be described as a representative example with reference to the drawings.

The air cylinder 521 includes a cylinder 521a and a piston rod 521c, and the piston rod 521c extends from a piston (not shown) that reciprocates inside the cylinder 521a by supply and discharge of compressed air, protrudes from the base 521b of the cylinder 521a, and reciprocates in synchronization with the piston.

The slide mechanism 52 further includes a cylinder block 522 to which the base 521b of the cylinder tube 521a is attached. The cylinder block 522 is mounted on the head main body 4. A cylinder base 512 of the holder moving mechanism 51 is attached to a distal end portion (an end portion on the opposite side of the air cylinder 521) of the piston rod 521 c. Thus, if the air cylinder 521 reciprocates, the holder moving mechanism 51 and the holder 50 move (slide) along the surface extending along the head main body 4 in synchronization.

The cylinder block 522 has through holes 522a formed in both sides thereof in the same direction as the direction of reciprocation of the piston rod 521c, with the mounting position of the cylinder tube 521a as the center. That is, 1 through hole 522a is provided on each side of the mounting position of the cylinder 521 a.

The slide mechanism 52 also includes a guide rod 523. The guide rod 523 is inserted into 1 of the 2 through holes 522a of the cylinder block 522.

The guide rod 523 has a stopper 523a at one end on the cylinder block 522 side, and the stopper 523a has a shape larger than the cross section of the through hole 522 a. The other end of the guide rod 523 is attached to the cylinder block 512 of the holder moving mechanism 51.

The stopper 523a is a member that defines a stroke (amount of movement) when compressed air is supplied to the air cylinder 521 and the piston rod 521c protrudes from the cylinder 521 a. Further, the stopper 523a is a member that defines the sliding amount of the holder 50. If the piston rod 521c protrudes and the retainer 50 slides, the guide rod 523 having one end attached to the retainer 50 is also guided by the retainer 50 and protrudes from the cylinder block 522, but after the stopper 523a comes into contact with the cylinder block 522, the retainer 50 stops.

The guide rod 523 is configured to guide the holder 50 so as not to be inclined with respect to the sliding direction of the holder 50 (the direction in which the piston rod 521c protrudes).

Further, the guide lever 523 also has a rotation preventing function of preventing the holder 50 from rotating about the reciprocating direction of the holder 50 (the direction in which the piston rod 521c protrudes). For example, if the piston rod 521c rotates about its central axis, the retainer 50 attached to the distal end portion of the piston rod 521c also rotates, and the orientation of the retainer 50 changes. The guide lever 523 is configured to restrict the rotation and maintain the orientation of the holder 50 in a predetermined direction.

As shown in fig. 4 and 5, the holding mechanisms 5a and 5b include slide mechanisms 52a and 52b for sliding the holders 50a and 50b in the a direction, respectively. That is, the head main body 4 is attached with the slide mechanisms 52a and 52b, and the holder moving mechanisms 51a and 51b are attached to the head main body 4 via the slide mechanisms 52a and 52 b. The sliding direction is generally a direction (generally horizontal direction) substantially orthogonal to a direction (vertical direction) in which the pair of dies K (see fig. 1) face each other.

The holding mechanisms 5C and 5d include sliding mechanisms 52C and 52d for sliding the holders 50C and 50d in the B direction substantially orthogonal to the a direction in a plan view (as viewed from the C direction). That is, the head main body 4 is attached with the slide mechanisms 52c and 52d, and the holder moving mechanisms 51c and 51d are attached to the head main body 4 via the slide mechanisms 52c and 52 d.

The holding mechanism 5g includes a sliding mechanism 52g that slides the holder 50g in a direction (D direction) different from the a direction and the B direction in a plan view (as viewed from the C direction). That is, the head main body 4 is attached with the slide mechanism 52g, and the holder moving mechanism 51g is attached to the head main body 4 via the slide mechanism 52 g. As described above, the a direction and the B direction are both directions in the horizontal plane in the use state, and the D direction may be a direction in the horizontal plane or a direction inclined from the direction in the horizontal plane.

The holding mechanisms 5e and 5f do not include the slide mechanism 52 and do not slide in the a direction or the B direction. The holding mechanisms 5e and 5f are attached to the head main body 4. The holding mechanisms 5e and 5f linearly reciprocate the holders 50e and 50f in the C direction toward the molding material M by the holder moving mechanisms 51e and 51 f.

(pressing mechanism)

As shown in fig. 8 (a) and 8 (b), each of the plurality of pressing mechanisms 6a, 6b, and 6c (6) includes a pressing piece 61a, 61b, and 61c (61), and a pressing piece moving mechanism 62a, 62b, and 62c (62) for moving the pressing piece 61. Since the pusher moving mechanisms 62a, 62b, and 62c have the same configuration, the pusher moving mechanism 62a will be described below as a representative.

The pushing member moving mechanism 62a includes 1 air cylinder 621, 1 cylinder block 622, 2 guide rods 623, and 2 stoppers 623 a. The pusher moving mechanism 62a has the same configuration as the holder moving mechanism 51, and therefore, the detailed description thereof is omitted. Here, the pusher moving mechanism 62 includes a mechanism for restricting the rotation of the pusher 61 formed by 2 guide rods 623, as well as the holder moving mechanism 51 including a mechanism for restricting the rotation of the holder 50 formed by 2 guide rods 513. Further, since the pusher 61 is smaller than the holder 50, in the case where the 2 guide bars 623 cannot be directly attached to the pusher 61, a block may be interposed therebetween, and the pusher 61 may be attached to the pusher moving mechanism 62 via the block. In fig. 3 to 5, the guide bar 623 is not shown. The guide lever 623 is an example of the "pusher rotation restriction mechanism" in the claims.

The pressing mechanism 6a includes a pressing member 61 a. Further, the pressing mechanism 6a includes 1 pressing member moving mechanism 62a that moves the pressing member 61a in the C direction. The urging member 61a is formed in a spherical shape. Further, the pusher 61a is provided on the end portion on the C2 direction side of the pusher moving mechanism 62 a.

The urging mechanism 6b includes an urging member 61 b. Further, the pressing mechanism 6b includes a pair of pressing member moving mechanisms 62b that move the pressing member 61b in the C direction. The pushing piece 61B is formed in a circular bar shape extending in the B direction. The pusher 61b is connected to the ends of the pair of pusher moving mechanisms 62b on the C2 direction side, and is provided so as to straddle the ends of the pair of pusher moving mechanisms 62b on the C2 direction side.

The urging mechanism 6c includes an urging member 61 c. Further, the pressing mechanism 6C includes a pair of pressing member moving mechanisms 62C that move the pressing member 61C in the C direction. The pushing piece 61c is formed in a circular bar shape extending in the a direction. The pusher 61C is connected to the ends of the pair of pusher moving mechanisms 62C on the C2 direction side, and is provided so as to straddle the ends of the pair of pusher moving mechanisms 62C on the C2 direction side.

The pusher 61a is arranged in a region in the a1 direction and the B2 direction among the 4 inner regions of the head main body 4. Further, the pusher 61B is arranged in a region in the a1 direction and the B1 direction among the 4 inner regions of the head main body 4. Further, the pusher 61c is arranged in a region in the a2 direction and the B2 direction among the 4 inner regions of the head main body 4. The pushers 61a to 61C are all arranged near the center of the molding material M in a plan view (as viewed from the direction C).

The spherical pressing tool 61a is configured to press the position of the molding material M before preforming corresponding to the vicinity of the portion where the surface K21, the surface K22, and the surface K23 of the molding material M positioned on the lower die K2 after preforming intersect at the time of preforming. The round bar-shaped pusher 61B extending in the B direction is configured to press the position of the molding material M before preforming, which corresponds to the vicinity of the portion where the surface K21 and the surface K22 of the molding material M on the lower die K2 after preforming intersect, during preforming. The round bar-shaped pusher 61c extending in the a direction is configured to press the position of the molding material M before preforming, which corresponds to the vicinity of the portion where the surface K21 and the surface K23 of the molding material M on the lower die K2 after preforming intersect, at the time of preforming.

The pushers 61a to 61C are configured to contact the molding material M from the C1 direction side and to push the molding material M toward the C2 direction side. Further, since the pushers 61a to 61c are portions directly contacting the molding material M, heat is carried away from the molding material M. Therefore, the thermal conductivity of at least the portion of the pressing members 61a to 61c in contact with the molding material M and the peripheral portion thereof is preferably lower than the thermal conductivity of the molding material M. If the thermal conductivity of the pressing pieces 61a to 61c is higher than the thermal conductivity of the molding material M, heat is taken away from the portions of the molding material M where the pressing pieces 61a to 61c contact, and there is a possibility that the surface of the compression molded body M1 (see fig. 1) may have a deteriorated appearance (wrinkles or the like occur on the surface).

Further, the pushing members 61a to 61c are preferably separated from the molding material M immediately after the completion of the preforming. It is preferable to use a fluororesin such as Polytetrafluoroethylene (PTFE) having high heat resistance and chemical resistance and a small friction coefficient as a material for forming the pressing members 61a to 61c (particularly, the portions of the pressing members 61a to 61c that directly press the molding material M). The portion of the pressing tools 61a to 61c that presses the molding material M refers to the portion of the pressing tools that comes into contact with the molding material M and the periphery thereof. The coating of the pushers 61a to 61c may be performed on the entire outer surfaces of the pushers 61a to 61c, or only on the portions of the pushers 61a to 61c that contact the molding material M and the periphery thereof.

In the present embodiment, the pusher 61a is a sphere (or a hemisphere) having a diameter of 40mm, for example. Further, the pusher 61b (pusher 61 c) is, for example, a round bar having a length of 150mm in the longitudinal direction and a diameter of 30 mm.

(control device)

The control device 3 shown in fig. 1 is configured to control the conveying operation and the preforming operation of the molding material M by the conveying device 100 a.

The controller 3 is configured to control the holding mechanisms 5a to 5g to heat the pressing members 61a to 61c by the heating device 101 without contacting the pressing members with the molding material M, and to hold the holders 50a to 50g for each portion of the molding material M in a molten and softened state. The control device 3 holds (supports) the respective parts of the molding material M by the holders 50a to 50g, and conveys the molding material M in a state supported by the conveying head 2 toward between the pair of dies K.

The controller 3 is configured to start preforming by controlling the holding mechanisms 5a to 5g and the pressing mechanisms 6a to 6c so that the pressing tools 61a to 61c for preforming press and deform the molding material M held by the holders 50a to 50g into a predetermined shape so as to follow the lower mold K2 before the molding material M comes into contact with the lower mold K2.

The controller 3 is configured to release the holding of the preformed molding material M by the holders 50a to 50g by controlling the holding mechanisms 5a to 5g, and to arrange the molding material M in the lower mold K2.

(preforming action by the conveying means)

Next, the preforming operation of the molding material M by the conveying device 100a will be described with reference to fig. 3 to 5. Fig. 3 and 4 show the state before the retainers 50a to 50d, 50g slide. Fig. 5 shows a state where the retainers 50a to 50d, 50g slide.

First, as shown in fig. 3 and 4, the molding material M held by the holding mechanisms 5a to 5g (holders 50a to 50 g) and supported by the transfer head 2 is transferred between the pair of dies K (see fig. 1) by the transfer device 100a in a state where the molding material M is not in contact with the pushers 61a to 61 c. At this time, the molding material M is supported by the holding mechanisms 5a to 5g on the transfer head 2 so as not to contact the pair of dies K.

As shown in fig. 9, the holders 50a to 50d, 50g are slid together toward the center of the molding material M in a plan view by the slide mechanisms 52a to 52d, 52 g. Accordingly, the parts of the molding material M held by the holders 50a to 50d, 50g also slide. Fig. 9 shows the positions of the respective pushers 61a to 61c and the respective holders 50a to 50g with respect to the molding material M disposed on the lower die K2 (see fig. 1) after the preforming is completed.

Specifically, the holders 50a, 50b are slid in the a2 direction by the slide mechanisms 52a, 52 b. Further, the holders 50c and 50d slide in the B1 direction (the direction orthogonal to the a2 direction in a plan view) by the slide mechanisms 52c and 52 d. Further, the holder 50g is slid in the D1 direction (a direction different from the a2 direction and the B1 direction in a plan view) by the slide mechanism 52 g.

Further, the retainer 50g sliding in the D1 direction has a shorter sliding distance than the retainers 50a and 50b sliding in the a1 direction. Therefore, when the sliding speed is the same, the retainer 50g sliding in the D1 direction reaches the target position (sliding stop position) earlier than the retainers 50a and 50b sliding in the a1 direction. Thus, the portion of the molding material M held by the retainer 50g sliding in the direction D1 forms the inner portion of the press formed body M1 (see fig. 1).

When the retainer 50a sliding in the a1 direction reaches the target position (slide stop position), the holding of the molding material M by the retainer 50a is released.

In parallel with the sliding movements, the holders 50e to 50g are moved in the direction C2 (in the direction of approaching the molding material M) by the holder moving mechanisms 51e to 51 g.

In parallel with the sliding movements, the pushers 61b and 61C are moved in the direction C2 (in the direction of approach of the molding material M) by the pusher moving mechanisms 62b and 62C.

Further, at the time point when the sliding movement (movement in the horizontal plane) and the movement toward the molding material M (movement in the direction C2) are completed and the holding of the molding material M by the retainer 50a is released, the molding material M is further separated from the pair of dies K.

Subsequently, the holding of the molding material M by the holder 50g is released. In parallel, the pusher 61a is moved in the direction C2 (the direction toward the molding material M) by the pusher moving mechanism 62 a. This presses the molding material M while contacting the lower die K2, thereby eliminating the floating of the molding material M and sufficiently adhering to the mold K.

Finally, the holding of the molding material M is released. That is, the holding of the molding material M by the holders 50b to 50f is released. Thereby, the molding material M is disposed along the lower die K2 as shown in fig. 2.

(Effect of the present embodiment)

In the present embodiment, the following effects can be obtained.

In the present embodiment, as described above, the holding mechanism 5 is provided with the holders 50a to 50g that hold the molding material M and the holder moving mechanisms 51a to 51g that move the holders 50e to 50g, and the pressing mechanism 6 is provided with the pushers 61a to 61c that are pressed in contact with the molding material M and the pusher moving mechanisms 62a to 62c that move the pushers 61a to 61 c. Since the holding mechanism 5 and the pressing mechanism 6 are provided separately, the pusher 61 can be separated from the molding material M except during the preforming, and therefore, the pusher 61 can be prevented from removing heat from the molding material M before the preforming. Therefore, the heat of the portion of the molding material M corresponding to the deformed portion of the lower die K2, which should most suppress the decrease in resin fluidity, is not unnecessarily removed by the pusher 61, and the problem of the decrease in pressure formability of the molding material M does not occur.

Further, by configuring such that the molding material M is conveyed between the pair of molds K opened by the conveying device 100a and the holding mechanism 5 and the pressing mechanism 6 are provided in the conveying device 100a at the same time, the conveying and preforming of the molding material M can be performed efficiently with a simple configuration, as compared with a case where the conveying mechanism and the holding mechanism 5 and the pressing mechanism 6 are provided in different devices.

As described above, the conveying device 100a can suppress a decrease in resin fluidity in the portion of the molding material M corresponding to the deformed portion of the lower mold K2, and can efficiently convey and preform the molding material M with a simple configuration, so that moldability of press molding can be improved, and as a result, a highly precise press-molded article (a press-molded article with good appearance) can be manufactured.

Further, since the conveying device 100a can directly press the molding material M by the pressing mechanism 6 while supporting it, it is possible to perform the preform without the molding material M contacting the lower mold K2. Accordingly, since the press molding can be performed immediately after the preformed molding material M is placed in the mold K, the moldability of the press molding can be improved, and as a result, a highly accurate press-molded article (a press-molded article with good appearance) can be manufactured.

In the present embodiment, as described above, the control device 3 for controlling the feeding operation and the arrangement operation of the molding material M is provided, and the control device 3 is configured to: by controlling the holding mechanism 5, each part of the molding material M is held by the plurality of holders 50a to 50g in a state where the pushers 61a to 61c are not in contact with the molding material M, and is conveyed between the pair of molds K while supporting the molding material M; controlling the holding mechanism 5 and the pressing mechanism 6 to start preforming by pressing and deforming the molding material M held by the plurality of holders 50a to 50g into a predetermined shape so as to follow one of the molds K, before the molding material M comes into contact with the one of the molds K; by controlling the holding mechanism 5, the holding of the molding material M after the preforming by the holders 50a to 50g is released, and the molding material M is arranged in one of the pair of dies K. Thus, by controlling the timing of the various operations by the control device 3, the pressing tool 61 is supported by holding the respective portions of the molding material M by the plurality of holders 50 in a state where the pressing tool 61 does not contact the molding material M before the molding material M is conveyed between the pair of molds K, and therefore, the pressing tool 61 can be prevented from removing heat from the molding material M even during conveyance.

In the present embodiment, as described above, the articulated robot 1 and the transport head 2 are provided, and the transport head 2 is attached to the articulated robot 1, and the plurality of holding mechanisms 5 and the 1 or more pressing mechanisms 6 are attached thereto. Thus, since the holding mechanism 5 and the pressing mechanism 6 are provided on the transfer head 2, the holding mechanism 5 and the pressing mechanism 6 can be smoothly interlocked with each other, and the operation time required for molding 1 press-molded body M1 can be shortened. This suppresses unnecessary heat dissipation from the molding material M, and thus can suppress a decrease in the temperature of the molding material M. As a result, a press-formed body M1 (high-precision press-formed body M1) having good appearance can be produced.

In the present embodiment, as described above, the head main body 4 is provided on the transport head 2, and the head main body 4 has a mesh-like skeleton structure to which the plurality of holding mechanisms 5 and the 1 or more pressing mechanisms 6 are attached. This can reduce the weight of the head body 4, and therefore can reduce the load acting on the articulated robot 1 when the head body 4 is operated. Therefore, the transport operation speed of the head main body 4 (transport head 2) can be made higher, and therefore the operation time required for molding 1 press-molded body M1 can be shortened. This suppresses unnecessary heat dissipation from the molding material M, and thus can suppress a decrease in the temperature of the molding material M. As a result, the press-formed body M1 having a better appearance (the press-formed body M1 having a higher accuracy) can be produced.

In the present embodiment, as described above, the head main body 4 includes the attachment portion 40, and the attachment portion 40 is provided in the vicinity of the edge portion of the head main body 4 having a mesh-like (lattice-like) skeleton structure and attached to the articulated robot 1. Thus, by providing the attachment portion 40 near the edge portion of the head body 4, only the head body 4 can enter between the dies K (the upper die K1 and the lower die K2), and the articulated robot 1 can prevent the multi-joint robot from entering between the dies K (the upper die K1 and the lower die K2), so that the distance of opening the dies (the distance between the upper die K1 and the lower die K2) can be minimized. Therefore, the time required for the mold opening operation can be shortened, and therefore the operation time required for molding 1 press-molded body M1 can be shortened. This suppresses unnecessary heat dissipation from the molding material M, and thus can suppress a decrease in the temperature of the molding material M. As a result, the press-formed body M1 having a better appearance (the press-formed body M1 having a higher accuracy) can be produced.

In the present embodiment, as described above, the articulated robot 1 includes the distal end joint portion 10c, and the head main body 4 is attached to the articulated robot 1 via the distal end joint portion 10 c. Thus, since the head body 4 is attached to the articulated robot 1 via the distal end joint portion 10c, the head body 4 can be moved flexibly and widely with respect to the articulated robot 1. This allows the preformed molding material M to be smoothly arranged in one of the pair of dies K.

In the present embodiment, as described above, the holder moving mechanisms 51a to 51g are provided with the guide rods 513, and the guide rods 513 restrict the holders 50a to 50g from rotating in the moving direction of the holders 50a to 50g by the holder moving mechanisms 51a to 51g, and maintain the orientations of the holders 50a to 50g in the predetermined direction; the pusher moving mechanisms 62a to 62c are provided with guide levers 623, and the guide levers 623 regulate the rotation of the pushers 61a to 61c in the moving direction of the pushers 61a to 61c by the pusher moving mechanisms 62a to 62c, and maintain the orientations of the pushers 61a to 61c in predetermined directions. Accordingly, by maintaining the respective orientations of the holders 50a to 50g and the pushers 61a to 61c by the guide rods 513 and 623, it is possible to suppress positional deviation of the holders 50a to 50g and the pushers 61a to 61c with respect to the molding material M.

In the present embodiment, as described above, the number of holding mechanisms 5 provided in the transport head 2 is made larger than the number of pressing mechanisms 6 provided in the transport head 2. This enables the molding material M to be stably held by the holding mechanisms 5, which are larger in number than the pressing mechanisms 6.

In the present embodiment, as described above, the articulated robot 1 is provided. Thus, the molding material M can be appropriately conveyed through various conveyance paths corresponding to the press-molded bodies M1 having various shapes.

In the present embodiment, as described above, the air cylinders 511 and 621 are provided in the holding mechanism 5 and the pressing mechanism 6, respectively. This makes it possible to linearly reciprocate the holders 50e to 50g and the pushers 61a to 61c with a simple configuration including the air cylinders 511 and 621. Further, since the weight of the transfer head 2 can be reduced, the load acting on the articulated robot 1 can be reduced when the head main body 4 is operated. As a result, the conveyance operation speed of the head main body 4 (conveyance head 2) can be made higher.

In the present embodiment, as described above, the holding mechanism 5 is provided with the slide mechanisms 52a to 52d, 52g, and the slide mechanisms 52a to 52d, 52g slide the holders 50a to 50d, 50g in the direction intersecting the moving direction of the holders 50a to 50d, 50g by the holder moving mechanisms 51a to 51d, 51 g. Accordingly, since the holders 50a to 50d, 50g can be slid by the slide mechanisms 52a to 52d, 52g and the distances between the holders 50a to 50d, 50g and the pushers 61a to 61c can be adjusted, the molding material M can be prevented from being excessively stretched and excessively thinned during the preforming. As a result, the press-formed body M1 can be manufactured with higher accuracy.

In the present embodiment, as described above, the air cylinders 521 are provided in the slide mechanisms 52a to 52d, 52 g. Thus, the holders 50a to 50d, 50g can be linearly reciprocated in the direction intersecting the moving direction of the holders 50a to 50d, 50g by the air cylinder 511 with a simple configuration constituted by the air cylinder 521. Further, since the weight of the transfer head 2 can be reduced, the load applied to the articulated robot 1 when the head main body 4 is operated can be reduced. As a result, the conveyance operation speed of the head main body 4 (conveyance head 2) can be made higher.

In the present embodiment, as described above, the holding mechanism 5 is provided with the holders 50a, 50B, the holders 50c, 50D, and the holder 50g, and further provided with the slide mechanisms 52a, 52B that slide the holders 50a, 50B in the a direction, the slide mechanisms 52c, 52D that slide the holders 50c, 50D in the B direction substantially orthogonal to the a direction in a plan view, and the slide mechanism 52g that slides the holder 50g in the D direction different from the a direction and the B direction in a plan view. Thus, the molding material M can be slid in the substantially orthogonal 2 direction and the direction different from the substantially orthogonal 2 direction in a plan view, and therefore, the molding material M can be preformed into a complicated shape such as a shape having an overlapped portion.

In the present embodiment, as described above, the pusher 61a is formed in a spherical shape, and the pushers 61b and 61c are formed in a circular rod shape. Thus, the molding material M having a more complicated shape can also be preformed by the pushers 61a to 61c having various shapes.

In the present embodiment, as described above, 1 or more holding needles 502 are provided in the holders 50a to 50g, and the holding needles are inserted into the molding material M to hold the molding material M. Thus, the molding material M can be held with a smaller contact area (contact area between the holder and the molding material M) than when the molding material M is held by abutting the flat surface, and therefore, the heat of the molding material M can be more effectively prevented from being carried away by the holder. As a result, even in the press molding M1 having a complicated shape, the heat is suppressed from being carried away from the molding material M, and the press molding M1 (high-precision press molding M1) having a good appearance can be manufactured.

In the present embodiment, as described above, the holder 50 is provided with the plurality of holding needles 502, and the plurality of holding needles 502 are arranged symmetrically with respect to the center lines of the holders 50a to 50g extending in the moving direction of the holders 50a to 50g by the holder moving mechanisms 51a to 51 g. Accordingly, when the molding material M is held by the holders 50a to 50g, the force can be uniformly applied to the molding material M, and therefore, the positional deviation of the molding material M and the extension of the molding material M due to the positional deviation can be suppressed.

In the present embodiment, as described above, the holding needle 502 is formed in an arc shape and can be configured to rotate in an arc shape. Thus, the holding pin 502 is rotated and inserted into the molding material M, so that the holding pin 502 is not easily pulled out from the molding material M, and the molding material M can be held more reliably.

Next, the results of actually conveying, preforming, and press-forming the molding material M by the conveying apparatus 100a of the present embodiment (examples 1 to 3) will be described.

(example 1)

A base material for a molding material comprising carbon fibers having a weight average fiber length of 20mm and a nylon 6 resin corresponding to a thickness of 2.5mm (a molding material thickness of 2.6 mm) of a press-molded article was used. This base material was cut into the same shape as the molding material M shown by the outer line in fig. 4, and heated so that the surface temperature of the base material became 290 ℃. The circular-arc needle at the tip of the holder is rotated to insert the needle into the substrate, and the conveying device is moved upward to lift the heated substrate. The circular-arc needle used in this case had a circular cross section with a diameter of 2mm, and the surface thereof was coated with PTFE. A molding material having a thickness of 2.5mm was lifted by an arc-shaped needle cut from the wire rod having a diameter of 40 mm.

Next, after the conveying device 100a having lifted the base material was moved from the die surface to a position 30mm above, the holder and the pusher were driven as described above, and the preliminary forming was performed between the pair of opened dies. Next, after the preforming is completed and the base material is placed in the mold, the mold is closed and pressurized immediately, and press-molding is performed to obtain a press-molded body. At this time, the temperature of the mold was adjusted to 150 ℃, and the press-molding was performed by pressing the press-molded body at a pressure of 20MPa in terms of the projected area of the press-molded body in the mold opening/closing direction. The pressing was maintained for 35 seconds, and the press molded body was taken out by opening the mold with the temperature of the press molded body at 180 ℃. Further, the series of molding operations was repeated 10 times, and it was confirmed that the series of molding operations could be operated with stability. As a result, the obtained press-molded article was free from the occurrence of overflow to the chamfered part (シャーエッジ) of the mold, the occurrence of a void due to the slipping of the base material on the vertical surface, and the opening of the mating surface, and a good press-molded article was obtained. In addition, in the obtained press-formed body, no occurrence of wrinkles was observed on the surface.

(example 2)

A base material for a molding material comprising carbon fibers having a weight average fiber length of 10mm and a nylon 6 resin corresponding to a thickness of 2.5mm (a molding material thickness of 2.6 mm) of a press-molded article was used. Preforming and press molding were carried out under the same conditions as in example 1 except that the base material was used, and the press molded body was molded. As a result, a press-molded article having a good quality equivalent to that of example 1 was obtained.

(example 3)

Using a molding base material containing carbon fibers having a weight average fiber length of 20mm and nylon 6 resin corresponding to a thickness of 3.5mm (molding material thickness of 3.6 mm) of the press-molded article, preforming and press-molding were carried out under the same conditions as in example 1 except for the above conditions, and the press-molded article was molded. As a result, a press-molded article having a good quality equivalent to that of example 1 was obtained.

(modification example)

The embodiments disclosed herein are illustrative in all respects and should not be considered as limiting. The scope of the present invention is defined by the claims rather than the description of the above embodiments, and includes all modifications (variations) within the meaning and scope equivalent to the claims.

For example, in the above-described embodiment, an example in which an articulated robot is used as the conveying apparatus main body of the present invention is described, but the present invention is not limited thereto. In the present invention, as in modification 1 shown in fig. 10, a device 201 that operates in the horizontal direction and the vertical direction with respect to the guide rail G may be used as the conveying device main body of the present invention. Although not shown, an orthogonal robot may be used as the transport apparatus main body of the present invention.

In the above embodiment, the example in which 1 pressing tool is provided in 1 pressing mechanism has been described, but the present invention is not limited to this. In the present invention, for example, as in the 2 nd modification shown in fig. 11, a plurality of pressing tools 261 may be provided in 1 pressing mechanism 206.

In the above embodiment, the holding needle is formed in an arc shape, but the present invention is not limited to this. In the present invention, for example, as in the modification 3 shown in fig. 12, the retaining needle 502a may be formed linearly. Alternatively, the holding needle may be formed into a shape obtained by dividing an ellipse or a quadratic curve, or the like.

In the above-described embodiments, the pressing tool is formed in a spherical shape or a round rod shape, but the present invention is not limited to this. In the present invention, for example, as in the 4 th modification shown in fig. 13 (a), the pusher 361a may be formed in a conical shape or a pyramidal shape. As shown in fig. 13 b, the pressing member 361b may be formed in a plate shape (rectangular parallelepiped shape).

In the above-described embodiment, an example in which the holding needle is formed into a slender conical shape (a shape in which the tip of the circular cross section is tapered) is described, but the present invention is not limited to this. In the present invention, for example, as in modification 5 shown in fig. 14, the retaining pin 502b may be formed in a plate shape (a shape in which the tip of the rectangular cross section is tapered).

In the above embodiment, the holding needle is formed in the shape of an arc of 1/4, but the present invention is not limited to this. In the present invention, the holding needle may be formed in an arc shape of 1/5, for example.

In the above-described embodiment, an example in which a plurality of holding needles are provided in 1 holder has been described, but the present invention is not limited to this. In the present invention, 1 holding needle may be provided in 1 holder.

In the above-described embodiment, an example in which a vertical mold press (vertical mold press) is used for press molding has been described, but the present invention is not limited to this. In the present invention, for example, a transverse clamping molding machine may be used for press molding.

In the above-described embodiment, an example is shown in which a plurality of pressing mechanisms are provided in the conveying device, but the present invention is not limited to this. In the present invention, 1 pressing mechanism may be provided in the transport device.

In the above-described embodiment, the head main body is configured by the skeleton structure, but the present invention is not limited to this. In the present invention, for example, the head main body may be formed in a flat plate shape.

In the above-described embodiment, an example in which the joint portion (distal end joint portion) of the present invention is provided on the conveying apparatus main body side has been described, but the present invention is not limited to this. In the present invention, the joint (distal end joint) of the present invention may be provided on the mounting portion side of the head main body.

In the above-described embodiment, the retainer has the retaining needle for retaining the molding material by the piercing, but the present invention is not limited to this. In the present invention, for example, the retainer may have a clip for holding the molding material by pinching.

In the above-described embodiment, the example in which the molding material does not contact the mold during the preforming is shown, but the present invention is not limited to this. In the present invention, the molding material may be brought into contact with the mold in the middle of the preforming period.

Claims (17)

1. A conveying device for supporting a molding material containing reinforcing fibers and a thermoplastic resin in a molten and softened state, conveying the molding material between a pair of molds opened by a mold, and disposing the molding material on one of the pair of molds,

the device is provided with a plurality of holding mechanisms and more than 1 pushing mechanism;

the holding mechanism includes a holder for holding the molding material and a holder moving mechanism for moving the holder;

the pressing mechanism includes a pressing member that is brought into contact with the molding material to press the molding material, and a pressing member moving mechanism that moves the pressing member,

a control device for controlling the conveying and arranging operations of the molding material;

the control device is configured to control the operation of the motor,

by controlling the holding mechanism, each part of the molding material is held by the plurality of holders in a state where the pusher is not in contact with the molding material, and the molding material is conveyed between the pair of dies while being supported by the holders;

controlling the holding mechanism and the pressing mechanism to start preforming, which presses the molding material held by the plurality of holders by the pressing tool and deforms the molding material into a predetermined shape so as to follow one of the pair of dies, before the molding material comes into contact with the one of the pair of dies;

the holding mechanism is controlled to release the holding of the molding material after the preforming by the retainer, and the molding material is arranged on one of the pair of dies.

2. The delivery device of claim 1,

the apparatus further comprises a conveying apparatus main body and a conveying head, wherein the conveying head is mounted on the conveying apparatus main body and is provided with the plurality of holding mechanisms and the more than 1 pushing mechanism.

3. The delivery device of claim 2,

the transport head includes a head main body having a mesh-like skeleton structure to which the plurality of holding mechanisms and the 1 or more pushing mechanisms are attached.

4. A conveying device according to claim 3,

the head main body includes a mounting portion provided in the vicinity of an edge portion of the head main body having the mesh-like skeleton structure and mounted to the conveying device main body.

5. The delivery device of claim 4,

the conveying device body or the mounting part is provided with a joint part;

the head main body is attached to the transport apparatus main body via the joint.

6. The delivery device of claim 2,

the holder moving mechanism includes a holder rotation restricting mechanism that restricts the holder from rotating in the moving direction of the holder by the holder moving mechanism and maintains the orientation of the holder in a predetermined direction;

the pusher moving mechanism includes a pusher rotation restricting mechanism that restricts the rotation of the pusher in the direction of movement of the pusher by the pusher moving mechanism and maintains the orientation of the pusher in a predetermined direction.

7. The delivery device of claim 2,

the number of the holding mechanisms provided on the transport head is larger than the number of the pressing mechanisms provided on the transport head.

8. The delivery device of claim 2,

the conveying device body is a multi-joint robot.

9. The delivery device of claim 1,

the holder moving mechanism and the pusher moving mechanism each have a pneumatic cylinder.

10. The delivery device of claim 1,

the holding mechanism includes a sliding mechanism that slides the holder in a direction intersecting a moving direction of the holder by the holder moving mechanism.

11. The delivery device of claim 10,

the aforementioned slide mechanism has an air cylinder.

12. The delivery device of claim 10,

the plurality of holding mechanisms each having the slide mechanism include: a1 st holding mechanism having a1 st holder and a1 st sliding mechanism for sliding the 1 st holder in a1 st direction; a2 nd holding mechanism having a2 nd holder and a2 nd sliding mechanism for sliding the 2 nd holder in a2 nd direction orthogonal to the 1 st direction in a plan view; and a 3 rd holding mechanism including a 3 rd holder and a 3 rd sliding mechanism for sliding the 3 rd holder in a 3 rd direction different from the 1 st direction and the 2 nd direction in a plan view.

13. The delivery device of claim 1,

the pressing tool is formed in a spherical shape, a conical shape, a pyramidal shape, a rod shape, or a plate shape.

14. The delivery device of claim 1,

the retainer includes 1 or more retaining needles that retain the molding material by being pierced into the molding material.

15. The delivery device of claim 14,

the aforementioned holder comprises a plurality of the aforementioned holding needles;

the plurality of holding needles are arranged symmetrically with respect to a center line of the holder, the center line extending in a moving direction of the holder by the holder moving mechanism.

16. The delivery device of claim 14,

the holding needle is formed in an arc shape and can be configured to rotate in an arc shape.

17. A transfer head for supporting a molding material in a molten and softened state, the molding material including reinforcing fibers and a thermoplastic resin,

the device is provided with a plurality of holding mechanisms and more than 1 pushing mechanism;

the holding mechanism includes a holder for holding the molding material and a holder moving mechanism for moving the holder;

the pressing mechanism includes a pressing member that is brought into contact with the molding material to press the molding material, and a pressing member moving mechanism that moves the pressing member,

a control device for controlling the conveying and arranging operations of the molding material;

the control device is configured to control the operation of the motor,

by controlling the holding mechanism, each part of the molding material is held by the plurality of holders in a state where the pusher is not in contact with the molding material, and the molding material is conveyed between the pair of dies while being supported by the holders;

controlling the holding mechanism and the pressing mechanism to start preforming, which presses the molding material held by the plurality of holders by the pressing tool and deforms the molding material into a predetermined shape so as to follow one of the pair of dies, before the molding material comes into contact with the one of the pair of dies;

the holding mechanism is controlled to release the holding of the molding material after the preforming by the retainer, and the molding material is arranged on one of the pair of dies.

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